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Millermatic 180 inconsistent welding

Purchased new about a year ago, had trouble right out of the box. I do wrought iron work and use a generator for power. Had been using my DVI 2 for years with a 7000w gen for years with no problem, just got tired of dragging it around. Decided to buy a 180 autoset and put it on a two wheeler for ease of moving around. Problem is my 7000w genny wont run it, kills the gen. Had to switch to a 10000w genny just to weld at 25 percent. Contacted miller about this issue to which they were no help at all, put the issue off as new technology.

My other issue with this machine is that on line voltage (230-240) it is so inconsistent. Will weld fine for a short time and then suddenly act like someone cranked up the wire speed and start banging the weld with wire or, just the opposite and burning the wire up to the tip. Again no help from Miller or my LWS. I am absolutely tired of jacking with this. I have been a dedicated Miller user for more than thirty years but now am seriously considering going red.

Ideas…….anyone?

TB 302
Sync 250 DX
MM 180 Auto
Lincoln tombstone
DVI-2
Why do we drive on a parkway and park on a driveway

Although I have encountered some issues with generator power if you are getting poor results on wall power then something is wrong. I would start by looking at any possible wire feeding issues, you would also want to check the work clamp (make sure it is in good shape and the cable connection is in good condition and tight). From there you may want to try a differnt gun if you haven't already tried that.

I will tell you this. People bash my Hobart welders but the welders are great and customer service is out of this world. They will stay with you until your problem is solved. The Tech i have dealt with was Bill and he was great.
Contact Miller and tell them your issues and let them lead you to the solution. If they don't i agree switch brands because their are to many top brands out their to be held up on a simple issue. I hate to hear about issues that the manufacturer won't help resolve. Shame on the dealers too.......Just saying......

Millermatic 180 inconsistent welding

Shouldn't it still be under warranty? And just to throw my other $.02 in. I agree with really checking your ground and your liner. Something could be causing it to hang. Also not trying to be a smart a$$ because you have been welding for yeas, could polarity be set wrong?

Millermatic 180 inconsistent welding

I've got a miller 252. I was having some of the exact same problems. It was constantly blowing back into the tip over and over. Some days it ran just fine though. In longer passes the lead would start shaking real bad and the wire would just seem to spit out and/or eventually fizzle out and quit feeding. I kicked that thing so many times I'm surprised it's not broken. Every test our weld supplier ran on it was negative for any defaults. Then our company moved to a new building and we haven't had any issues with it. We came to the conclusion that it was most likely the power supply to the building.